Fuel Gas Pressure Control Solutions
for Fired Heaters and Boilers
Solutions for safer and more reliable operation of fired heater fuel gas systems.
Prevent process downtime by keeping your
critical heaters online.
Fuel Gas Systems
Fired heaters and boilers are essential components of most refineries, chemical plants and power generation facilities.
Whether helping to power a steam turbine generator or the direct heating of hydrocarbons to make gasoline, the
fundamentals of fuel gas pressure control are relatively standard across a wide range of fired heater applications.
Power Generation
Boiler
Steam
Steam
Turbine
Generator
Electricity
FUEL GAS
refining Process
Fired
Heater
Distillation
Tower
Crude Oil
FUEL GAS
Product
Products
Fuel Gas Pressure Control Challenges
• Inadequate speed of response of pressure control devices
causing unplanned shutdowns
• Poor fuel gas quality or lack of routine maintenance leading
to equipment failures
• Poor pressure control caused by improper equipment selection
Fuel Gas Source
Although natural gas is the fuel most
commonly used in a fired heater, many
refineries and chemical plants mix process
waste gases into their fuel systems.
These process gases may contain heavy
hydrocarbons that can cause build-up in the
fuel gas lines. For sites that use waste gas,
a higher rate of residue build-up is typical
and must be accounted for in the pressure
regulator selection and configuration.
Fuel Gas Header Pressure Control
Because a fuel gas header can supply fuel to one or multiple fired
heaters, reliability, speed of response, maintainability and noise
limits are important design considerations when selecting a
pressure control device.
Fired
Heater
Fuel Gas Header
Pressure
Regulator
Burner Gas
Pressure Control
Accuracy, speed of
response and turndown are
key design considerations
for burner gas pressure
control. Steady and reliable
fuel gas pressure aids the
heater start-up process and
ensures efficient fuel gas
control to a fired heater.
Pressure
Regulator
Burner Gas
FUEL GAS
SOURCE
Control Valve
Minimum Fire
Pressure Regulator
Pressure
Regulator
Pilot Gas
Fired Heater #2
Fired Heater #3
Pilot Gas Pressure Control
For pilot control, self-operated regulators are
commonly selected because they are easier
to maintain, less complex and have very high
turndown capabilities when compared to other
pressure control devices.
real world Solutions. Emerson™ develops fuel gas pressure control solutions by
first understanding the real-world requirements and challenges.
minimizing the dangers associated with
equipment start-up is a top priority.
Fuel Gas Solutions
minimum Fire Pressure Control
Complicated burner management systems can hinder your ability to
start a heater safely and quickly. An API 556-recommended minimum
fire pressure regulator is essential when the fuel gas control valve lacks
sufficient turndown to light the first burner.
This regulator not only helps minimize the complexity of the burner
management system, but also reduces operator interaction during
start-up. Simply set the regulator to the required setpoint during
commissioning and it can remain untouched through multiple start-ups.
Fired
Heater
Fuel Gas
Header
Pressure
Regulator
Pressure
Regulator
Burner Gas
FUEL GAS
SOURCE
Control Valve
Minimum Fire
Pressure Regulator
Pressure
Regulator
Pilot Gas
Exceeding Standards. Emerson™ regulators are designed to both meet and exceed
applicable standards, helping keep your process compliant and safe.
monitor Setup
A monitor setup provides predictable control for certain pressure
regulator failure modes without sacrificing pressure control performance.
Commonly used in natural gas distribution by gas utilities, a monitor
setup uses regulators in series to provide a layer of redundancy in the
event the primary pressure regulator ceases to control downstream
pressure. Monitor setups are recommended for use in fuel gas header
and burner gas pressure control applications.
Fired
Heater
Working Monitor
Regulator Regulator
Working Monitor
Regulator Regulator
Pressure Monitor
Regulator Regulator
Burner Gas
FUEL GAS
SOURCE
Fuel
Gas
Header
Control Valve
Minimum Fire
Pressure Regulator
Pressure
Regulator
Pilot Gas
reliable Customized
Systems.
For more than 80 years,
Emerson™ has worked with
customers to design monitor
systems that provide a reliable
pressure control solution. In
addition to keeping your
process online, monitor
systems are easier to
maintain and operate
than other failure
protection methods.
optional Features
wireless Position Indication
End users are often hesitant to use a pressure regulator, viewing it as a closed
system that makes it difficult to determine if a regulator is working properly.
Wireless position indicators can be used to detect and troubleshoot regulator
problems on your existing control system before they impact your operation.
They can be mounted on a variety of regulators to indicate real-time regulator
performance, long-term degradation or a step change in process conditions.
Slam-Shut
The Emerson™ slam-shut valve is a mechanical device that will “slam shut”
when it senses a high- or low-pressure event. With Class VI shutoff capability,
the slam-shut valve can be used to increase the safety of your fired heater
shutdown system.
A slam-shut valve can be installed independently or attached to an existing
pressure regulator valve body to save space and reduce piping modifications.
A solenoid valve can also be added to connect the slam-shut to an existing
safety system.
noise reduction
High-pressure drops increase the possibility of high
noise – a big concern for fuel gas heater pressure
control when downstream demand can fluctuate.
Noise attenuation options can reduce noise by up to 10
to 20 dB depending on the application.
Innovative Technologies.
Emerson offers innovative
solutions like remote
monitoring options and
emergency shutdown
capability that can
help minimize
downtime and
improve plant safety.
over 50% of unplanned shutdowns are related to human factors. minimize unscheduled down time
by increasing your knowledge. rely on Emerson™ for expert assistance and training.
Unparalleled Support
Expert help when you need it the most.
Emerson state-of-the art flow and materials labs provide an extensive
worldwide network of engineers, application experts and sales professionals
to help you size, select and troubleshoot your pressure regulators.
Emerson test and evaluation teams provide flow, material and
environmental testing under real-world operating conditions before
you place them in your application.
Training to help you effectively maintain your systems.
No other regulator manufacturer in the world offers more products and
local services dedicated to safe, effective applications than Emerson.
We strive to be the leader in training pressure control personnel.
Emerson offers a wide array of onsite and offsite training for all levels of your
organization. Together with our local business partners we work with you to
develop training that fits the needs of your team, whether it is application
training for engineers, operational training for operators or maintenance
training for technicians. With our courses, your personnel can learn to:
• Perform maintenance on regulators
• Troubleshoot field problems
• Understand the influence of the service environment
on regulator performance
• Properly size regulators
Global Sales and Service.
Emerson sales and
service offices are located
strategically around the
globe in North America,
Latin America, Europe, Asia
Pacific and the Middle East
and Africa. With more than
2000 technical experts
in nearly 200 offices,
application support
is just a call or
click away.
Top-rated Products for Boilers, Burners and Fuel Gas applications
SElF-oPEraTEd rEGUlaTorS
Type 912n
Type HSr
Type y600a
Body Size
NPS 1/4 or 1/4 x 3/8
Body Size
NPS 3/4 or 1 / DN 20 or 25
max Inlet
250 psig / 17.2 bar
max Inlet
150 psig / 10.3 bar
outlet range
3 in. w.c. to 5 psig /
7 mbar to 0.35 bar
outlet range
4 in. w.c. to 7 psig /
10 mbar to 0.48 bar
max Flowrate
1030 SCFH / 27.6 Nm3/h
max Flowrate
6660 SCFH / 178 Nm3/h
CS200/CS400 Series
CS800 Series
Body Size
NPS 3/4, 3/4 x 1,
3/4 x 1-1/4, 1, 1 x 1-1/4,
1-1/4, 1-1/2 and 2 /
DN 20, 20 x 25, 20 x 32,
25, 25 x 32, 32, 40 and 50
Body Size
NPS 3/4, 3/4 x 1 or 1 NPT /
DN 20, 20 x 25 or 25
max Inlet
125 psig / 8.6 bar
outlet range
4 in. w.c. to 2.2 psig /
10 mbar to 0.15 bar
max Flowrate
4800 SCFH / 129 Nm3/h
Type 66
Body Size
NPS 1-1/4, 1-1/2 or 2 /
DN 32, 40 or 50
Body Size
NPS 2, 3, 4 / DN 50,
80, 100
max Inlet
125 psig / 8.6 bar
max Inlet
10 psig / 0.69 bar
max Inlet
125 psig / 8.6 bar
outlet range
3.5 in. w.c. to 10 psig
/ 9 to 690 mbar
outlet range
4 in. w.c. to 5 psig /
10 mbar to 0.35 bar
outlet range
3.5 in. w.c. to 5.5 psig /
9 to 380 mbar
max Flowrate
36,270 SCFH / 974 Nm3/h
max Flowrate
77,500 SCFH / 2077 Nm3/h
max Flowrate
12,000 SCFH / 322 Nm3/h
Speed of response
FASTEST
Self-Operated
Speed of response is important in regulator
selection for fuel gas services due to the fast
load or demand changes typically required
Pressure-Loaded
by fired heater applications. By design,
fired heater start-ups and shutdowns can
be abrupt. The regulator will need to sense
FASTER
this load change and respond quickly before
the fuel gas pressure reaches the low or
Loading Style Pilot-Operated
(also known as Two-Path Style)
without Recommended Construction
Unloading Style Pilot-Operated
(also known as Flexible Element Style or Boot Style)
high safety trip point. Each of the regulator
designs have different speed of response
characteristics and the figure to the right
provides some general guidance when it
comes to pressure regulator selection.
Loading Style Pilot-Operated
(also known as Two-Path Style)
with Recommended Construction
FAST
Control Valve
133 Series
627 Series
Body Size
NPS 2 / DN 50
Body Size
NPS 3/4, 1, 2 / DN 20,
25, 50
max Inlet
150 psig / 10.3 bar
max Inlet
2000 psig / 138 bar
outlet range
2 in. w.c. to 60 psig /
5 mbar to 4.1 bar
outlet range
5 to 500 psig /
0.34 to 34.5 bar
max Flowrate
372,000 SCFH /
9960 Nm3/h
max Flowrate
179,000 SCFH /
4797 Nm3/h
mr95 Series
T205
Body Size
NPS 1/4, 1/2, 3/4, 1, 1-1/2,
2 / DN 15, 20, 25, 40, 50
Body Size
NPS 3/4 or 1 / DN 20 or 25
max Inlet
200 psig / 13.8 bar
max Inlet
1000 psig / 68.9 bar
outlet range
1 in. w.c. to 7 psig /
2 mbar to 0.48 bar
outlet range
2 to 400 psig /
0.14 to 27.6 bar
max Flowrate
12,919 SCFH / 346 Nm3/h
max Flowrate
510,000 SCFH /
13,600 Nm3/h
PrESSUrE loadEd/PIloT-oPEraTEd rEGUlaTorS
1098 Series
99 Series
Body Size
NPS 1, 2, 3, 4, 6, 8 x 6, 12 x
6 / DN 25, 50, 80, 100, 150,
200 x 150, 300 x 150
Body Size
3/4, 3/4 x 1, 3/4 x 1-1/4,
1, 1 x 1-1/4, 1-1/4, 1-1/2,
2/ DN 20, 20 x 25, 20 x 32,
25, 25 x 32, 32, 40, 50
max Inlet
1000 psig / 69.0 bar
max Inlet
400 psig / 27.6 bar
outlet range
2 in. w.c. to 100 psig /
5 mbar to 6.9 bar
outlet range
4 in. w.c. to 300 psig /
10 mbar to 20.7 bar
max Inlet
125 psig / 8.6 bar
minimum differential
requirement
minimum differential
requirement
0.75 to 10 psi / 0.05 to
0.69 bar depending on
construction
1 to 28 psi / 0.07 to1.93 bar
depending on construction
outlet range
1 to 20 psig / 0.07 to 1.4 bar
max Flowrate
17,600 SCFH / 472 Nm3/h
recommended
Construction
recommended Construction
Fast open or fast closing Type 61 pilot option/
quick-open cage/lightest possible main spring,
dual pilot construction
FEaTUrES avaIlaBlE:
CP200/CP400 Series
Body Size
NPS 2 / DN 50
Fast Open or Fast Closing
pilot option
Wireless
Slam Shut
Monitor
Noise Attenuation
Travel Indicator
Top-rated Products for Boilers, Burners and Fuel Gas applications
PrESSUrE loadEd/PIloT-oPEraTEd rEGUlaTorS
Ezl Series
299H Series
EzH Series
Body Size
NPS 1-1/4, 1-1/2, 2 /
DN 32, 40, 50
Body Size
NPS 2, 3 and 4 /
DN 50, 80 and 100
Body Size
NPS 1, 2, 3 and 4 /
DN 25, 50, 80 and 100
max Inlet
175 psig / 12.1 bar
max Inlet
290 psig / 20.0 bar
max Inlet
1500 psig / 103 bar
outlet range
3.5 in. w.c. to 60 psig /
9 mbar to 4.1 bar
outlet range
7 in. w.c. to 300 psig /
17 mbar to 20.7 bar
outlet range
14.5 to 1160 psig /
1 to 80 bar
minimum differential
requirement
minimum differential
requirement
minimum differential
requirement
1.5 psi / 0.10 bar
2.9 to 0.39 psi / 0.20 to
0.03 bar depending on
construction
12.8 to 16.4 psi / 0.88 to
1.13 bar depending on
construction
recommended
Construction
recommended
Construction
Fast open or fast closing
Type 61 pilot option
Type 32A or PRX / 131
recommended
Construction
Dual registration using
3/4 in. piping
Ezr Series
Fl Series
Type 310a
Body Size
NPS 1, 2, 3, 4, 6 and 8 /
DN 25, 50, 80, 100, 150
and 200
Body Size
NPS 1, 2, 3, 4, 6, 8 and 10
/ DN 25, 50, 80, 100, 150,
200 and 250
Body Size
NPS 1, 2, 3, 4, 4 x 6 /
DN 25, 50, 80, 100,
100 x 150
max Inlet
1050 psig / 72.4 bar
max Inlet
1480 psig / 102 bar
max Inlet
1480 psig / 102 bar
outlet range
6 in. w.c. to 1000 psig /
15 mbar to 68.9 bar
outlet range
14.5 to 1160 psig /
1 to 80 bar
outlet range
10 to 750 psig /
0.69 to 51.7 bar
minimum differential
requirement
minimum differential
requirement
7.3 to 14.5 psi / 0. 5 to
1.0 bar depending on
construction
minimum differential
requirement
12 to 43 psi / 0.8 to 3.0 bar
design
Unloading Style
15 psi / 1.03 bar
recommended
Construction
recommended
Construction
Turbine startup trim
Type 32A or PRX/131
FEaTUrES avaIlaBlE:
Wireless
Slam Shut
Monitor
Noise Attenuation
Travel Indicator
Installation Tips
Internal Sensing Units
Piping should be
a straight run for
8 to 10 pipe diameters
downstream of
the regulator
Proper installation of a fuel gas application minimizes shutdowns
and restarts and helps ensure safe equipment operation, with less
burner and flame fluctuations.
Vent Lines
1.
Best practices suggest that vent piping should be as large as
the nominal size of the vent connection and increased one
nominal pipe size for every 10 feet of linear pipe. (One elbow is
equivalent to 3 feet of linear pipe.)
2. Verify the vent is oriented downward to protect it from the
weather on applications without vent piping and ensure there
is no moisture in the spring case
Improving Speed of Response for a
Pilot-Operated Regulator
1.
Speeding up closing
• Increase size of pilot restrictor
• Consider a pilot with a quick dump feature
such as the 61 Series or Type 32A
2. Speeding up opening
• Reduce size of pilot restriction
• Increase differential pressure
• Consider a faster pilot or larger pilot orifice size
• Add an additional supply pilot which will quickly
increase loading pressure
External Sensing Units
Control Line
Control line should be as large as
the nominal size of the line
connection and increase one nominal
pipe size for every 20 feet of linear
pipe. (One elbow is equivalent to
3 feet of linear pipe).
The amount of
downstream pipe
volume also impacts
speed of response.
All installations should
be field tested to ensure
proper response.
8 to 10 pipe diameters
from any restrictions,
elbows or swages.
Sense location should be
close to demand source
for quicker reaction.
Emerson™ sales, service and technical support are as close as your telephone or on the web, anywhere in
the world. Our distribution network offers a full complement of expert sales and support staff and more than
2000 technical experts strategically located across nearly 200 offices worldwide.
For more information, visit www.emersonprocess.com/regulators.
Emerson Process management
regulator Technologies, Inc.
Emerson Process management
regulator Technologies, Inc.
Americas
worldwide Headquarters
3200 Emerson Way
McKinney, TX 75070 USA
T: +1 800 558 5853
T: +1 972 548 3574
F: +1 972 542 6433
Europe
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T: +65 6770 8337
Middle East
T: +971 4811 8100
D352277X012 © 2015 Emerson Process Management Regulator Technologies, Inc. All rights reserved. Printed 7/15.
Fisher, Emerson Process Management, and the Emerson Process Management design are marks of one of the Emerson Process Management group
of companies. All other marks are the property of their respective owners. The contents of this publication are presented for informational purposes
only, and while every effort has been made to ensure their accuracy, nothing herein is to be construed as a warranty or guarantee, express or implied,
regarding the products or services described herein or their use, performance, merchantability or fitness for a particular purpose. Individual results
may vary. Responsibility for the proper selection, use and maintenance of any product or service remains solely with the purchaser and end user.